A mobile cart has a battery assembly, which includes an on-board charger for selectively recharging one or more batteries to ensure constant operation of the powered equipment provided on the cart. The battery assembly possesses a removable battery configuration and is operated by a Battery Control System (BCS). The BCS is an intelligent control system for removable batteries and battery cell packs to provide an improved system of charging and discharging the individual batteries.
Legal claims defining the scope of protection. Each claim is shown in both the original legal language and a plain English translation.
1. A power system for a mobile cart, comprising: a battery assembly comprising one or more rechargeable batteries, a battery support for supporting each respective one of said batteries wherein said battery support is mountable on a mobile cart and said respective battery is removeably engageable with and disengagable from said battery support from an exterior of said mobile cart, said battery assembly including a battery connector for each said battery which is engageable with said battery when said battery is installed on said respective battery support, each said battery being individually removable from said battery support independently of any other said battery supported by said battery support; a battery control system for recharging said batteries, which has a control unit comprising a power supply removeably connectable to external power, a charge controller receiving power from said power supply when connected to external power and controlling battery charging and discharge, a first power outlet receiving power under the control of said charge controller to provide power to electrical equipment on a mobile cart, a power port for each said battery support, which is selectively connectable to said battery through said battery connector, power flow through each said power port being controlled by said charge controller to control charging of each said battery by external power and discharging of each said battery, wherein discharging of said battery supplies battery power to said first power outlet for use by cart equipment, said control unit permitting removal of any said battery during charging of any said battery on said battery support; and said charge controller charging a respective said battery to an upper charging threshold, wherein said upper charging threshold reflects a battery charge below which said battery is chargeable at a first charging rate and above which said battery charges at a slower second charging rate, each said battery being charged to said upper charging threshold before said charge controller begins to charge each said battery above said upper charging threshold to a full charge using said second charging rate, said charge controller permitting charging of one said battery during removal of any other said battery from said battery support.
A mobile cart power system includes a battery assembly with removable rechargeable batteries, each on its own support, accessible from outside the cart. Each battery connects to the system via a connector on the support. A battery control system (BCS) recharges the batteries. The BCS has a power supply connectable to external power, a charge controller, a power outlet for equipment, and a power port for each battery. The charge controller manages charging and discharging, sending battery power to the outlet. Batteries can be removed during charging of others. The charger initially charges each battery to an "upper charging threshold" quickly, then more slowly to full charge.
2. The power system for a mobile cart according to claim 1 , wherein said battery control system determines if external power is present, wherein external power is used to supply power to said first power outlet and charge a selected one of said batteries by said charge controller.
The mobile cart power system (as described with removable batteries, a battery control system, and tiered charging) checks if external power is present. If so, external power is used both to power the cart's equipment via the first power outlet and to charge the batteries using the charge controller.
3. The power system for a mobile cart according to claim 2 , wherein if external power is not present, said charge controller determines which said battery to use, wherein said charge controller determines if each said battery is below a minimum charge which establishes that a battery is discharged, said charge controller using said battery which has the lowest battery charge first to supply said battery power to said first power outlet.
The mobile cart power system (with removable batteries, a battery control system, external power detection, and tiered charging) will, if external power is unavailable, determine which battery to use. It checks each battery's charge level against a "minimum charge" threshold. The battery with the lowest charge is used first to power the cart's equipment via the first power outlet.
4. The power system for a mobile cart according to claim 3 , wherein if one said battery is at or below the minimum threshold, then said charge controller uses another said battery having a higher battery charge above the minimum charge to supply said battery power to said first power outlet.
In the mobile cart power system (with removable batteries, a battery control system, external power detection, tiered charging, and lowest-charge-first discharge), if one battery's charge is at or below the minimum charge threshold, the system uses another battery that has a higher charge above the minimum threshold to power the equipment connected to the first power outlet.
5. The power system for a mobile cart according to claim 3 , wherein if two said batteries are above the minimum charge, said charge controller using said battery with a lower battery charge to supply said battery power to said first power outlet.
In the mobile cart power system (with removable batteries, a battery control system, external power detection, tiered charging, and lowest-charge-first discharge), if two or more batteries have a charge level above the minimum charge threshold, the charge controller selects the battery with the lowest charge to supply power to the equipment connected to the first power outlet.
6. The power system for a mobile cart according to claim 5 , wherein said battery in use will continue to be used to supply said battery power to said first power outlet until its charge decreases to the minimum charge, at which time said charge controller switches to another said battery to supply said battery power to said first power outlet.
In the mobile cart power system (with removable batteries, a battery control system, external power detection, tiered charging, and lowest-charge-first discharge), once a battery is selected for use, that battery continues to power the equipment through the first power outlet until its charge drops to the minimum charge. Then, the charge controller switches to another battery to provide power.
7. The power system for a mobile cart according to claim 1 , wherein when external power is not present, said charge controller switches so as to receive power from one said battery or another said battery and route this battery power to said first outlet port.
The mobile cart power system (with removable batteries and a battery control system), when external power is not present, switches between batteries to receive power from one or another and routes this battery power to the first power outlet port for powering connected equipment.
8. The power system for a mobile cart according to claim 7 , wherein when charging with external power, said battery with the higher state of charge is charged first, provided said battery has a charge level that is not more than said upper charging threshold and the other said battery has a charge level less than said upper charging threshold.
The mobile cart power system (with removable batteries, a battery control system, and battery switching) charges the battery with the higher state of charge first, only if that battery's charge is not above the upper charging threshold, and the other battery's charge is below the upper charging threshold. This prioritizes charging the less-full battery first, up to the initial, faster charging level.
9. The power system for a mobile cart according to claim 8 , wherein said upper charging threshold is dictated by battery design and chemistry.
In the mobile cart power system (with removable batteries, a battery control system, battery switching, and charging priority), the upper charging threshold (the level to which batteries are rapidly charged before slower top-off charging) is determined by the battery design and chemical properties.
10. The power system for a mobile cart according to claim 1 , wherein two or more of said batteries are provided, and wherein, when said battery that is being charged reaches the upper charging threshold, said charge controller switches to charging another said battery up to said upper charging threshold thereof.
The mobile cart power system (with removable batteries and a battery control system) has two or more batteries. When the battery currently being charged reaches the "upper charging threshold" (the point where charging slows down), the charge controller switches to charging another battery, bringing it up to its own upper charging threshold.
11. The power system for a mobile cart according to claim 10 , wherein after each of said two or more said batteries have been charged to said upper charging threshold, said charge controller continuing to charge one said battery to a full charge, and then charges a next said battery to a full charge until all of said batteries have been charged to said full charge.
In the mobile cart power system (with multiple removable batteries and tiered charging), after each battery has been charged to its upper charging threshold (the point where charging slows), the charge controller continues to charge one battery to its full charge. Then it charges the next battery to its full charge, repeating until all batteries are fully charged.
12. The power system for a mobile cart according to claim 1 , wherein said charge controller initially receives data on a cycle count for each said battery from a data storage associated with said battery, and then compares cycle counts for each said battery, and when the cycle count of one said battery exceeds the cycle count of the other said battery by more than a defined cycle differential, then said battery with the lower cycle count is used first in both discharging to supply power to said first power outlet and recharging by external power.
The mobile cart power system (with removable batteries and a battery control system) initially reads cycle count data for each battery. It compares these cycle counts. If one battery's cycle count exceeds another's by a defined differential, the battery with the *lower* cycle count is used first for both discharging (powering the cart) and recharging. This prioritizes batteries with fewer cycles to equalize wear.
13. The power system for a mobile cart according to claim 1 , wherein two said charge controllers are provided to provide the option of charging two said batteries simultaneously.
The mobile cart power system described previously (with removable batteries and a battery control system) includes *two* charge controllers. This enables the option of charging two batteries simultaneously, improving charging speed.
14. The power system for a mobile cart according to claim 13 , wherein said control system determines when power used by said first power outlet is off or minimal, and then both said charge controllers operate to charge two said batteries simultaneously, and determines when said first power outlet is in use and supplying significant power, and then said charge controllers charge only one said battery.
The mobile cart power system (with removable batteries, a battery control system, dual charge controllers, and tiered charging) monitors the power usage of the equipment connected to the first power outlet. When that power usage is off or minimal, *both* charge controllers operate to charge two batteries simultaneously. When the equipment *is* using significant power, the charge controllers charge only one battery to dedicate more power to the connected equipment.
15. The power system for a mobile cart according to claim 1 , wherein if one said battery is manually removed from said battery support during charging or discharging, said charge controller automatically detecting removal of said battery and switching charging or discharging to another said battery.
The mobile cart power system (with removable batteries and a battery control system) automatically detects if a battery is manually removed during charging or discharging. Upon detection, the charge controller immediately switches charging or discharging operations to another installed battery.
16. The power system for a mobile cart according to claim 15 , wherein said power system is operable with one or two said batteries installed in two said battery supports.
The mobile cart power system (with removable batteries, a battery control system, and battery removal detection) is designed to operate correctly with either one or two batteries installed. The system adapts to the number of batteries available.
17. A method for operating a power system for a mobile cart, said power system comprising a battery assembly comprising a battery support and one or more rechargeable batteries which are supported in said battery support and are removable from said battery support independently of any other said battery, and a battery control system for recharging said batteries, which has a control unit comprising a power supply removeably connectable to external power, a charge controller receiving power from said power supply when connected to external power and controlling battery charging and discharge, a first power outlet receiving power under the control of said charge controller to supply power to electrical equipment on a mobile cart, a power connector for each said battery, which is selectively connectable to said battery to permit removal of any said battery independent of any other said battery during said battery charging and discharging, said method comprising the steps of: controlling power flow through each said power connector by said charge controller to control charging of each said battery by external power and discharging of each said battery, which provides battery power to said first power outlet for use by cart equipment; initiating charging of each said battery by said charge controller when external power is present; continuing charging of a respective one of said batteries by said charge controller until a charge level of said battery reaches a respective upper charging threshold for said battery being charged, wherein said upper charging threshold reflects a battery charge below which said battery is chargeable at a first charging rate and above which said battery charges at a slower second charging rate; after said one battery reaches said upper charging threshold, discontinuing charging of said one battery and initiating charging of the other of said batteries to said upper charging threshold; and after each said battery is charged to said upper charging threshold, then charging one of said batteries by said charge controller to a full charge and then charging any remaining said batteries to said full charge.
A method for operating a mobile cart power system with removable batteries and a battery control system involves controlling power flow through each battery connector to manage charging (using external power) and discharging (to power the cart's equipment). Charging is initiated when external power is available. Charging continues to an "upper charging threshold" at a first, faster rate, then at a slower rate until fully charged. When external power is present, batteries will be charged up to their upper charging threshold before being charged at a slower rate until completely charged. After a battery is charged up to its upper charging threshold, the charging will be discontinued for that battery and then another battery will be charged until its upper charging threshold is reached. After the upper charging thresholds of all batteries are reached, the batteries will be charged to their full charge.
18. The method according to claim 17 , including the step of discontinuing charging of said battery upon reaching a full charge thereof, and then initiating charging of the other said battery from said upper charging threshold up to said full charge.
The method for operating a mobile cart power system (involving removable batteries, a battery control system, and tiered charging) includes stopping charging a battery upon reaching its full charge. Then, it initiates charging of another battery from its upper charging threshold up to its full charge. This focuses on fully charging batteries sequentially.
19. The method according to claim 17 , including the step of determining if external power is present, and using said external power to supply power to said first power outlet and to charge each selected one of said batteries by said charge controller.
The method for operating a mobile cart power system (involving removable batteries, a battery control system, and tiered charging) includes checking for the presence of external power. This external power is then used both to supply power to the first power outlet (powering the cart's equipment) and to charge the batteries using the charge controller.
20. The method according to claim 19 , wherein if external power is not present, said charge controller determining which said battery to use, wherein said charge controller determines if each said battery is below a minimum charge which establishes that a battery is discharged, and said charge controller using said battery which has the lowest battery charge first to supply said battery power to said first power outlet.
The method for operating a mobile cart power system (involving removable batteries, a battery control system, external power detection, and tiered charging) specifies that, if external power is *not* present, the charge controller determines which battery to use. It checks each battery's charge level against a "minimum charge." The battery with the lowest charge is used *first* to supply power to the cart equipment through the first power outlet.
21. The method according to claim 20 , wherein if one said battery is at or below the minimum threshold, then said charge controller uses another said battery having a higher battery charge above the minimum charge to supply said battery power to said first power outlet, and if two said batteries are above the minimum charge, said charge controller using said battery with a lower battery charge to supply said battery power to said first power outlet.
The method for operating a mobile cart power system (involving removable batteries, a battery control system, external power detection, tiered charging, and lowest-charge-first discharge) dictates that if one battery's charge is at or *below* the minimum threshold, another battery with a *higher* charge above the minimum is used. If *two* batteries are above the minimum, the battery with the *lower* charge is used to power the first power outlet.
22. The method according to claim 21 , wherein said battery in use will continue to be used until a charge level of said battery decreases to the minimum charge, at which time said charge controller switches to another said battery.
The method for operating a mobile cart power system (involving removable batteries, a battery control system, external power detection, tiered charging, and lowest-charge-first discharge) ensures that a battery in use for powering the cart will continue to be used until its charge level drops to the minimum charge. At that point, the charge controller switches to another battery to supply power.
23. The method according to claim 17 , wherein when charging, said battery with the charge level is charged first, provided its charge level is not more than said upper charging threshold and the other said battery has a charge level less than said upper charging threshold.
In the method for operating a mobile cart power system (involving removable batteries, a battery control system, and tiered charging), when charging, the battery with the *higher* state of charge is charged *first*, *provided* that its charge level is not more than the upper charging threshold and the other battery's charge level is less than the upper charging threshold.
24. The method according to claim 17 , wherein said charge controller initially receives data on a cycle count for each said battery from a data storage associated with said battery, and then compares cycle counts for each said battery, and where the cycle count of one said battery exceeds the cycle count of the other said battery by more than a defined cycle differential, then the battery with the lower cycle count is used first in both discharge and recharge.
The method for operating a mobile cart power system (involving removable batteries, a battery control system, and tiered charging) involves the charge controller initially receiving data on each battery's cycle count from a data storage. It then compares these counts. If one battery's cycle count exceeds the other's by more than a defined differential, the battery with the *lower* cycle count is used *first* in both discharging and recharging to promote even wear.
25. A power system for providing battery power to mobile equipment, comprising: a battery assembly comprising one or more rechargeable batteries, a battery support for each respective one of said batteries wherein said battery support is mountable on a support frame and said respective battery is removeably engageable with said battery supportindependently of any other said battery engaged with said battery support, a battery connector for each said battery which is engageable with said battery when said battery is installed on said respective battery support; a battery control system for recharging said batteries, which has a control unit comprising a power supply removeably connectable to external power, a charge controller receiving power from said power supply when connected to external power and controlling battery charging and discharge, a first power outlet receiving power under the control of said charge controller to provide power to electrical equipment on said support frame, a power connector port for each said battery support, which is selectively connectable to said battery through said battery connector, power flow through each said power connector port being controlled by said charge controller to control charging of each said battery by external power and discharging of each said battery, wherein discharging of said battery supplies battery power to said first power outlet for use by cart equipment, said control unit permitting removal of any said battery during charging of any other said battery on said battery support; and said charge controller charging a respective said battery to an upper charging threshold, wherein said upper charging threshold reflects a battery charge below which said battery is chargeable at a first charging rate and above which said battery charges at a slower second charging rate, each said battery being charged to said upper charging threshold before said charge controller begins to charge each said battery above said upper charging threshold to a full charge using said second charging rate wherein after said one battery reaches said upper charging threshold, said charge controller discontinuing charging of said one battery and initiating charging of the other of said batteries to said upper charging threshold; and after each said battery is charged to said upper charging threshold, said charge controller then charging one of said batteries by said charge controller to a full charge and then charging any remaining said batteries to said full charge.
A power system for mobile equipment comprises a battery assembly with removable rechargeable batteries, each individually removable from its support. Each battery connects through a connector. A battery control system (BCS) recharges the batteries using a power supply connectable to external power, a charge controller, and a power outlet for equipment. The charge controller manages charging and discharging, sending battery power to the outlet. The BCS allows removing any battery during the charging of other batteries. The charger initially charges each battery to an "upper charging threshold" quickly, then more slowly to full charge. After a battery reaches the upper threshold, charging switches to another battery until all are at the threshold, then each is fully charged in sequence.
Cooperative Patent Classification codes for this invention. Click any code to explore related patents in that topic.
April 29, 2013
July 11, 2017
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